Alkyl Hydroperoxide Purification by Water Extraction
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Solution Overview
Problem
Existing methods for purifying alkyl hydroperoxides, such as tert-butyl hydroperoxide, are inadequate in removing dialkyl peroxides, leading to impurity contamination, decreased purity, and increased production and environmental costs, while degrading the physicochemical properties of the hydroperoxides, which affects the quality of crosslinking agents and polymerization initiators.
Innovation Solution
A process involving extraction with water to separate alkyl hydroperoxide and dialkyl peroxide phases, followed by concentration and optional settling stages, results in an aqueous composition rich in alkyl hydroperoxide with minimized dialkyl peroxide content, maintaining the hydroperoxide's properties for effective use in crosslinking agents and polymerization initiators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If base (KOH or NaOH) is added to form water-soluble alkyl hydroperoxide salt for separation from dialkyl peroxide, then separation efficiency is improved, but significant dilution of alkyl hydroperoxide occurs, decreasing its effectiveness and complicating storage and transportation
Solution Approach 1:
The invention changes the pH parameter of the aqueous phase by adjusting it to between 2 and 6 (preferably 3 to 5) before extraction. This parameter adjustment optimizes the distribution coefficient of alkyl hydroperoxide between the aqueous and organic phases, allowing efficient separation from dialkyl peroxide while maintaining high concentration of the hydroperoxide in the purified aqueous phase, thus avoiding the dilution problem associated with base addition.
2Ease of operation
If alkyl hydroperoxide salt is acidified to reform alkyl hydroperoxide for subsequent synthesis, then the hydroperoxide is recovered, but large amounts of saline aqueous effluents are formed that must be treated, increasing production costs and environmental impact
Solution Approach 1:
The invention extracts alkyl hydroperoxide directly into the aqueous phase under controlled pH conditions (pH 2-6) from the beginning, rather than forming a salt and then acidifying it. This eliminates the need for acidification step entirely, preventing the formation of large amounts of saline aqueous effluents. The dialkyl peroxide remains in the organic phase and is separated, while the aqueous phase containing the purified alkyl hydroperoxide can be directly used or concentrated without generating harmful waste streams.
3Manufacturing precision
If conventional purification methods are used to remove dialkyl peroxide impurities, then purity of alkyl hydroperoxide is improved, but physicochemical properties of the hydroperoxide are degraded, affecting the quality of crosslinking agents and polymerization initiators
Solution Approach 1:
The invention carefully controls the pH parameter of the aqueous phase between 2 and 6 (preferably 3 to 5) during extraction. This optimized pH range ensures high purity separation of alkyl hydroperoxide from dialkyl peroxide while maintaining the integrity of the hydroperoxide's physicochemical properties. The controlled acidic conditions prevent degradation reactions that would occur with strong base treatment, preserving the hydroperoxide's effectiveness for subsequent synthesis of crosslinking agents and polymerization initiators.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process achieves a high-purity alkyl hydroperoxide solution with less than 0.1% dialkyl peroxide, reducing production costs, environmental impact, and safety risks, while preserving the hydroperoxide's quality for efficient use in polymerization and crosslinking processes.
Implementation Method 1
a) at least one stage of extraction, carried out with water, of the mixture so as to obtain a first phase rich in alkyl hydroperoxide and a second phase rich in dialkyl peroxide
Implementation Method 2
b) at least one stage of concentration of the content of alkyl hydroperoxide in the first phase obtained in stage a) so as to obtain two new phases, known as third and fourth phases
Implementation Method 3
c) optionally a stage of separation by settling of the third phase so as to obtain a fifth and sixth phase
Data Source
AI summary
The present invention relates to a method for purifying a mixture containing at least one alkyl hydroperoxide, preferably tert-butyl hydroperoxide or tert-amyl hydroperoxide, and at least one corresponding dialkyl hydroperoxide, said method comprising at least one step of extraction with water and at least one separation step which is carried out within the aqueous phase, obtained following the extraction step, in order to recover an aqueous solution which is rich in alkyl hydroperoxide. The invention also relates to an aqueous composition which is rich in alkyl hydroperoxide and contains at least 0.1% by weight of dialkyl peroxide in relation to the total weight of the composition.